Tufting method and apparatus



Aug, 22, 1967 .1. T. SHORT 3,336,889

TUFTING METHOD AND APPARATUS Filed Sept. ll, 1964 5 Sheets-Sheet l ATTORNE YS Aug. 22, W67 1. T. SHORT 3,336,889

TUFTING METHOD AND APPARATUS Filed Sept. ll, 1.964 5 Sheets-Sheet 2 INVENTOR.

Joe T. Short AT TOR/VE YS Aug. 22, 1967 J. T. SHORT 3,336,889

TUFTING METHOD AND APPARATUS Filed Sept. ll, 1964 5 Sheets-Sheet E VINVENTOR.

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ATTURND/ Aug. 22, 1967 .1. T. SHORT TUFTING METHOD AND APPARATUS Filed Sept. ll, 1964 5 Sheets-Sheet 4 iiiillli R M O` MMO/V wmf m5 T. e b J//W B 7 8 mw J /O 0108 QU ATTORNEYS Aug. 22, 1967 J. T. SHORT 3,336,889

TUFTING METHOD AND APPARATUS Filed Sept. ll, 1964 5 Sheets-Sheet 5 INVENTOR.

J0@ T. ShOV l ATTRNEY United States Patent O 3,336,889 TUFTING METHOD AND APPARATUS Joe T. Short, West Point, Ga., assignor, by mesne assignments, to Callaway Mills Company, La Grange, Ga., a corporation of Georgia Filed Sept. 11, 1964, Ser. No. 395,851 22 Claims. (Cl. 112-266) This invention relates to a method and apparatus for making pile fabric and more particularly concerns a tufting machine and a process for producing a tufted fabric.

In the past, tufting machines have been used Widely for the production of carpets, rugs, scatter rugs, throw rugs, bedspreads, blankets and the like. Until recently these tufting machines have substantially all been of the general type including a heavy frame having a drive shaft housing in its upper portion, the housing containing a drive shaft or crank shaft for reciprocating in a vertical path a transversely disposed needle bar. The needle bar, in turn, carries a plurality of evenly spaced downwardly projecting aligned needles for insertion through a base fabric or backing sheet moved therebeneath. The conventional tufting machine also includes a bank of loopers, corresponding in number to the needles, with or without associated knives, the loopers being reciprocated in timed relationship with the reciprocation of the needle bar for catching and temporarily holding the yarns carried through the base fabric by the needles.

If the conventional tufting machine is to be employed for producing patterned loop pile fabric in which loops of different heights defining the pattern are formed, yarn control mechanism or feed mechanism is mounted adjacent the drive shaft housing of the tufting machine for feeding the yarns at varying rates from the creel to 4the needles in accordance with a predetermined pattern. If only a uniform` pile height is desired in the fabric, yarn feed mechanism consisting of a pair of feed rollers mounted on the tufting machine is employed for feeding the yarns in uniform amounts from the creel or beams to the needles of the tufting machine.

In the event the yarns fed by any one of the feed mechanisms, of necessity, follow circuitous or tortuous routes, passing through various holes in guide bars and past yarn jerkers and the like, to terminate by passing through the eyes of the needles. Such paths while recognized as abrading the yarns and being undesirable, are dictated by the fact that the position of the drive shaft housing prevented a more direct or shorter path for the yarns to the needles. Furthermore, to provide a uniform back stitch in the fabric produced on conventional tufting machine, there should be some restraint on the yarns leading to the needles, so as to tighten the yarns against the base material on the down stroke of the needle. It is, therefore, seen that the yarn employed in conventional tufting machines are subjected to sharp bends and tension suiiicient, in some instances, to break fibers in the yarns, reduce the diameter of the yarns and unravel the yarns.

In the conventional tufting machine, the stroke of the needles usually must exceed the highest pile height contemplated for the resulting fabric, since the needles must clear the base fabric `on their up stroke and be so positioned, at or approaching bottom dead center, that the `looper bills pass above the eyes of the needles for engaging the yarns carried by the needles. Furthermore, the looper bills must` be respectively set with infinite care so as to pass closely adjacent the needles during each cycle of the machine, without splitting the yarns carried by the.

needles or striking and breaking the needles.

The high center of gravity and heavy moving mechanisms, required to reciprocate the needles and synchronize `of the lubricant leaking 3,336,889 Patented Aug. 22, 1967 ICC lbe carried on a heavy concrete slab bolted in position to reduce to a minimum the vibration of the machine when running. Even so, such vibrations are transmitted to the yarns, causing intertwining of adjacent yarns, and are transmitted to the loopers and needles causing misalignment and resulting in broken or bent parts.

The long and cir-cuitous paths followed by the yarns and the passing of the yarns over, around and through metal surfaces while under varying tensions, causes abrasion of the yarn, numerous breaks in the yarns, and parting of the glue joints, unraveling and over twisting of the yarns, knotting, pulling of fibres and the arresting of the yarn in its travel. Indeed, in some instances, where short staple libres are employed, and untwsting is prevalent, the tufting operation becomes so time consuming due to breaks in the yarns as to `be impractical.

A conventional tufting machine is usually operated at a speed of between 400 and 700 r.p.m., and it is not unusual for such a tufting machine to have well over onehalf of its time as down time, either for rethreading of the yarns through the various holes or for mechanical maintenance. Thus, it is seen that, while the production of a conventional tufting machine far surpasses the production of a loom, it is still a highly ineicient, complicated ann troublesome mechanism and the production of seconds may result from the various problems described above, which seconds may also be produced as a result from the drive shaft housing onto the fabric therebeneath.

The quality of the tufted fabric, in certain instances, is also a problem, when produced on the prior art conventional machines; since the yarn, having been drawn through several small apertures and having been subjected to no iluiiing action, may not spread to any appreciable extent to hide the backing material or base fabric, may not be as full in appearance as could be obtained and may contain loose and disoriented fibres.

More recently, tufting machines having hollow needles reciprocated for insertion of the yarn through the base fabric or backing material have been employed on a commercial scale. These hollow needle machines employ compressed air directed through the needles for creating loops, the length of which are dictated by the amounts of yarns fed into the needles by the yarn feed mechanisms.

The use of such machines improves the quality ofthe goods produced and increases the speed and reliability of the tufting machine; however, such hollow neeedle machines still require an overhead crank shaft or main drive shaft for reciprocating the needle bar which carries the hollow needles, and they require flexible hosings for supplying air to the Lmanifold surrounding portions of the needles. Also, as a result of the positioning of the main drive shaft in the upper portion of the hollow needle machine, the paths of travel of the yarns from the yarn feed mechanism to the needles, and the tortuous or circuitous nature of the paths of travel of such yarns have not been materially changed. Furthermore, the problem of lubricant leaks from the drive shaft housing is present.

It is therefore, seen that in either type of prior art machine hereiubefore described, there is a substantial vertical distance between the mounting feet which support the machine and the reciprocating and rotating elements of the machine. This distance magnifies the vibration of the machine which is a factor in limiting the speed of operation of the machine. Such machines also require a substantial distance and a number of apertures through which the yarns m-ust pass from the feed mechanism to the needles. Furthermore, both types of tufting machines require reciprocation of the needle. In both types of machines, during the first half of the cycle of the needle, the needle is moved downwardly in the direction of feed of the yarn. During the latter half of the cycle, the needle is moved upwardly, in a direction opposite the direction of feed of the yarn. This upward movement of the needle in some instances causes slackening of the yarn. Thus, the yarns fed to the. adjacent needles may become intertwined. If fibrous yarns are employed, the intertwined yarns may become firmly stuck together, thereby causing yarn breaks or malfunctioning of the loop forming operation. Both types of machines require over-the-fabric lubrication of the reciprocation and rotating parts, with the possibility, ever present, of the lubricant leaking onto the fabric.

Briefly, the present invention, which obivates the above noted problems, includes a method of tufting in which are the steps of advancing a base fabric or backing material past stationary yarn discharging means, successively forcing at least a portion of the base fabric or backing material onto and then off of the yarn discharging means, discharging strands of yarn of prescribed lengths from the yarn discharging means while the base fabric or backing material is on the yarn discharging means, thereafter removing the backing material, advancing the same along its path of travel and repeating the operations.

In general terms the apparatus of the presen-t invention for accomplishing this method includes a frame through `which a base fabric or backing material is passed in a relatively horizontal normal linear path, being fed by and held taut by rollers disposed along transverse axes on opposite sides of a tufting zone. Above the backing material, and disposed transversely across the path of travel of the base fabric, is the yarn discharging means having a plurality of evenly spaced hollow needles disposed perpendicular to the path of travel of the backing material, either transversely aligned in a single row or in staggered arrangement providing a plurality of transverse rows of needles. The needles are usually vertically disposed and, contrary to prior art beliefs and practices, do reciprocate. Instead, the needles remain essentially stationary, their lower pointed ends or tufting ends terminating in a tufting zone longitudinally between the feed rollers and in close proximity to the normal path of the backing material.

Fluid differential pressure applied either continuously or intermittently to the yarns urges yarns from the needles. Above the needles and supported in fixed relationship to the frame is the yarn control mechanism which is preferably of the type which provides for single end or two end control. The discharge end of yarn control mechanism is disposed closely adjacent the entrance end of the hollow needles so that the yarns, discharged from the yarn control mechanism, pass in substantially direct parallel paths, preferably paths aligned with, or essentially aligned wi-th, the axesof the hollow needles, into the passageways of the needles. Since there is no intervening mechanism which must be circumvented, the paths of travel of the yarns from the yarn control mechanism to 'the needles is short and essentially straight with nothing to cause unraveling, twisting, or abrading of the yarns between the yarn feed lmechanism and the needles.

The distance between the discharge end of the yarn control mechanism and the entrance end of the needles is fixed and remains constant throughout the entire operation, whereby the distance of travel of each yarn from the discharge end of the yarn control mechanism to the entrance end of the needle is approximately equal for all yarns.

The elimination of the slackening of the yarn on the up stroke, and the fact that all yarns travel approximately the same short distance and are not stretched .to any appreciable extent during their movement from the yarn v control mechanism to their needle, contribute to a clear and accurate pattern definition in the resulting fabric.

Tufting is accomplished in the tufting zone by reciprocating, toward and away from the tufing ends of the needles, progressive transverse intermediate portions of the backing material held taut, the deection or deviation of the reciprocated portion of the backing material from its normal path of travel preferably being of small amplitude, only sufficient for the pointed ends of the needles to penetrate the backing material and introduce short looped portions of yarns to the other side of the backing material, whence the compressed air, emerging from the needles, extends the length of the loops to the limits .permitted by the feed of the respective yarns by he yarn con- -trol mechanism. For purpose of reciprocating the transverse portion of the base fabric, a deflector mechanism is provided which includes a crank shaft or main drive shaft below the backing material driving a pitman mechanism and a fabric deflector carried by the pitman mechanism.

Thus, upon rotation of the drive shaft, the deflector is reciprocated to deiiect progressive transverse portions of the fabric in the tufting zone toward the needles. A stripper plate on the needle side of the backing material, reciprocated in timed relationship to the reciprocation of the deector, urges the transverse intermediate portions of the fabric backing material away from the needles after each transverse row of loops is formed.

It is therefore an object of the present invention to provide an improved tufting method and an improved tufting machine which is less expensive to manufacture and operate, which requires a minimum of maintenance and which will consistently and efliciently produce a pile fabric of high quality.

It is another object of the present invention to provide an improved tufting machine which has lower power requirements and which is less subject to vibration than conventional tufting machines.

It is still another object of the present invention to provide an improved tufting machine which has a minimum yarn travel path between yarn control mechanism and yarn discharging means and in which drag on the yarn at the yarn discharging means is substantially eliminated.

It is therefore an object of the present invention to provide an improved tufting machine in which precise timing of the movement of various cooperating elements, such as needles and loopers, is not necessary.

It is a further object of the present invention to provide an improved tufting machine of reduced height and with its center of gravity sufliciently low to reduce vibration to a minimum.

Another object of the present invention is to provide a tufting machine which will operate at very high speed for extended periods of time.

Another object of the present invention is to provide a tufting machine and method of tufting which will produce a much higher volume of tufted goods than conventional machines.

Another object of the present invention is to provide a tufting machine and a method of tufting which will eliminate or reduce to a minimum the tendency of the yarns in the tufting operation to unravel, twist, untwist, knot, break, stretch, intertwine, abrade, or vibrate.

Another object of the present invention is to provide a tufting machine and a method of tufting in which the resulting fabric has an improved pattern definition.

Other objects, features and advantages of the present invention will become apparent from the following description when taken in conjunction with the accompanying drawings wherein like characters of reference designate corresponding parts and in which:

FIG. 1 is a partially broken, front elevational view of a tufting machine constructed in accordance with the present invention;

FIG. 2 is a side elevational view of those portions of the machine illustrated in FIG. 1;

PIG. 3 is a cross sectional view taken substantially along line 3-3 in FIG. 1;

FIG. 4 is an enlarged fragmentary vertical sectional View of a portion of the needle carriage of the machine illustrated in FIG. 1, showing in cross section one needle carried by the needle carriage;

FIG. 5 is an enlarged fragmentary vertical sectional View of a detail, showing from one side a pair of needles of the machine illustrated in FIG. 1, a portion of the deflector means and the backing material after several loops have been formed in the backing material; and,

FIG. `6 is a rear elevational View of those portions of the machine illustrated in FIG. 5.

FIG. 7 is a fragmentary longitudinal Vertical sectional view of a modified form of the present invention.

FIG. 8 is a fragmentary front elevational view of a portion of those parts shown in FIG. 7.

Referring now in detail to the embodiment chosen for the purpose of illustrating the invention, it being understood that, in its broader aspects, the invention is not limited to the exact details herein depicted, numeral 10 denotes generally the frame of the tufting machine of the present invention. The frame 10, as seen -best in FIG. 1, includes a pair of opposed upstanding end members 11, both of which are hollow tubular elements provided at their lower ends with feet or base plates 12 by means of which the end members 11 are secured to a suitable floor.

Vertically immediately above the feet or base plates 12 is a drive shaft housing 13 which, as seen in FIG. 3, is a hollow tubular member having an access opening 14 closed by an access plate 15 along one side. Bolts 16 secure plate 15 in place. The ends of the housing 13 are connected to the inner plates of the end members 11, and a drive shaft 17 is carried for rotation in the housing 13 -by a plurality of pillow blocks, such as pillow blocks 18 seen in FIG. 3.

`011e end of drive shaft 17 protrudes through one of the end members 11 and is provided, outwardly of the end member 11, with a pulley 19, seen in FIG. l. Pulley 19 is driven by belts 20 from a pulley 21 on the shaft of a motor 22. Motor 22 is mounted on the end member 11 adjacent the protruding end of the shaft 17. Therefore, upon energization of motor 22, shaft 17 is rotated.

Between the pillow blocks, such as 4block 18, the shaft 17 is provided with a plurality of circular eccentric cams, such as cam 23 in FIG. 3. Surrounding the periphery of each cam 23 is a bearing 24 to which is attached an upstanding pitman 25 to the upper end of which is pivotally connected the lower end of an upstanding reciprocator rod 26. Rod 26 is slide'ably carried by a bushing 27 and protrudes outwardly therebeyond. The upper ends of all reciprocator rods 26 terminate in a common horizontal plane so as to carry a mounting block 28. As seen in FIG. 1, the mounting block 28 extends transversely across the machine, parallel to and above the housing 13, terminating inwardly of the end members 11.

Secured to the upper surface of the reciprocator block 28 is a dellector bar 29, the function of which is to deflect or deviate, in a reciprocatory manner, a transverse central portion of a base fabric or backing material 30 from its normally substanitally horizontal linear path through the machine, the deection or deviation being of small amplitude for purposes to 'be described hereinafter. The deflector bar 29 is at least as long as the width of the backing material and is substantially rectangular in cross-section. The upper corner edges 31 of the deilector bar 29 are rounded while the upper surface of the deilector bar 29 is substantially ilat so as to permit the backing material 30` to slide over the bar 29 without danger of -being torn.

The upper portion of the deiiector bar 29, i.e., the portion next adjacent the backing material, is provided with a plurality of adjacent, parallel, upwardly opening,

loop receiving slots or recesses 32, the function of which is to receive the yarns inserted through the base fabric in the tufting zone. Slots 32 therefore extend in parallel longitudinal direction with respect to the base fabric 30. The formation of the slots 32 leaves, between the slots 32, a plurality of upstanding ribs 33 which. -are integral with and connected by their lower edges to the lower portion of the bar 29. The arrangement is such that between each pair of r-ibs 33 there is a slot 32. The ribs 33 are each preferably the same width and the slots 32 `are each preferably the same width; therefore, the slots 32 are equally spaced from each other throughout the length of the Ideflector bar 29.

It will be understood by those skilled in the art that for purpose of construction, the reciprocator block 28 may be separated into a plurality of end-to-end blocks (not shown) and that the `deector bar 29, likewise, may be separated into -a plurality of end-to-end bars (not shown).

For feeding the base fabric or back-ing materials 30 through the machine, between the end members 11, and over the upper surface of bar 29 in a predetermined or prescribed preferably linear horizontal path, a pair of infeed rollers 34 and a pair of outfeed rollers 35 are provided on opposite sides of the deflector bar 29. The rollers 34 are supported from the end members 11 by a pair of forwardly extending flanges, such as flange 36, seen in FIG. 3. The rollers 35 Iare supported between a pair of rearwardly extending flanges 37, mounted on end members 11 as best seen in FIG. 3. The flanges 36 and 37' are in opposed relationship to each other transversely and longitudinally so as to support the rollers 34 and 35 in parallel relationship to each other and parallel to the deilector bar 29. The upper per-ipheries of the upper rollers 34 and 35 are in about the same horizontal plane as the upper surface of the deflector -bar 29 when the deiiector bar 29 is at bottom `dead-center.

The backing material 30, as is usual, passes below roller 34 and rearwardly around approximately 180 of the lower rol-ler 34, passing between the two rollers 34 and thence around the front of the uppe-r roller 34, exiting tangentially from the upper roller 34 and passing to the upper periphery of the upper roller 35 along an approximately linear path. The backing .material 30 then passes around the rear 180 of the upper roller 35, between the two rollers 35 and then around the front periphery of the lower roller 35. Thence the base material 30 passes to the usual inspection frame (not shown) and to `a take-up mechanism (not shown).

The rollers 34 and 35 are rotated in a manner to move the backing material in the direction of the arrow 38 in FIG. 3 in timed relationship to the reciprocation of the deflector bar 29. For this purpose, continuous chains 40 and 41, seen best in FIG. 2, drive sprockets 42 and 43 on the shafts of the upper rollers 34 and 35- while the.

upper and lower rollers 34 are synchronized for rotation by intermeshing gears 44 and upper and lower rollers 35 are synchronized for rotation by inter-meshing gears 45.

Chains 41 and 42 are driven from the main drive shaft 17 through a suitable gearing arrangement (not shown), the drive being such as to impart a continuous feed for the backing material 30, timed or synchronized with the reciprocation of the deector bar 29. The relationship between the feed of backing material 30` by rollers 34 and its takeup by rollers 35 is such as to maintain the backing material 30 taut and yet sufficiently loose to permit the deliector bar 29 to deflect 1a narrow central transverse portion of the backing material from its normal path.

It will be understood that the expression continuous feed or that the backing material is fed continuously, contemplates that -the backing material is fed at either a uniform rate or intermittently so as to pass prescribed equal amounts of backing material 30- over the deilector bar 29 in successive cycles of the machine, whereby successive transverse increments of the backing material 30 are deflected upwardly by the deflector bar 29.`

Yarn Dscharging Means Above the backing material 30 is the yarn discharging means, the function of which is to hold the increments or strands of yarns S in equally spaced transversely aligned positions so that the successive portions of backing material 30 deflected by the deector bar 29 will successively receive therethrough these held increments of yarns 50 for creating longitudinally parallel rows of loops, such as loops 51 and 52, seen lin FIGS. 5 and 6, the adjacent loops, such as loops 51 and 52, being connected by back `stitches 53.

The yarn discharging means is similar to the yarn discharging means disclosed in U.S. Patent No. 3,089,442, except that, in the present invention, the needle carrier or needle `bar 54 holds the needles 55 in a stationary position over the backing material 30 and the tufting is accomplished in a tufting zone by the reciprocation of successive portions of the backing material 30.

In more detail, the needle carrier or needle -bar 54 is transversely extending, tubular rectangular member suspended from a cross bar 56, the ends of the cross bar 56 being secured to the end members 11. The needle carrier 54 includes a top plate 57 and a bottom plate 58 disposed in parallel spaced relationship, the front and back of the needle carrier 54 being closed by end plates 59 and l60, respectively, which 4may have suitable gaskets, such as gasket 59a. The ends of the needle carrier 54 are closed by caps, such as cap 61.

Air or other fluid is intermittently introduced into the chamber of needle carrier 54 from a source of compressed air or uid (not shown) via a conduit, such as pipe 62, or a plurality of such pipes communicating with the charnber of needle carrier 54. Each pipe 62 is provided with a solenoid valve 63 controlled by a solenoid 64. Solenoid 64 is connected to a source of current (not shown) in series through a brush 65 which rides on a disc shaped commutator `66 on the main `drive shaft 17. A portion of the periphery of the commutator 66 is insulated so that the solenoid 64 is energized to open the valve 63 only during a portion of each cycle of the machine, the energization of the solenoid 64 being timed by the main drive shaft 17 so that airis supplied to the chamber commencing during the latter portion of the upstroke of the deflector bar 29 and terminating during the beginning of the down stroke of the deflector bar 29.

As is customary to obtain narrow spacing between adjacent -rows of loops, the needles 55 are staggered with v respect to each other, the needles 55 being arranged, for

example, in two transverse rows or banks above the deector bar 29.

Each needle 55 is an elongated hollow tubular member which, as best seen in FIG. 4, is formed of one or several parts. In the embodiment chosen for illustration, the needle 55 includes a central shank having a reduced diameter cylindrical base or lower end portion 71 which terminates inwardly of the lower end of the shank in a peripheral shoulder 72. Above the shoulder 72 is a cylindrical body portion 73 having at its upper end a frustoconical upwardly tapered shoulder 74. Above the shoulder is an upper intermediate portion 75 of a diameter slightly less than the diameter of base 71, the intermediate portion 75 terminating at the cap 76 of the shank. Cap 76 is of a diameter as large or larger than the diameter of body portion 73 and is provided with a peripheral groove for receiving an annular washer or packing ring 77. Above the peripheral groove on the periphery of the cap y76 is a vertical recess 78 which is adapted to receive the tip of a set screw 79.

The central portion along the axis of the shank is bored to provide a straight yarn passageway 80 throughout the length of the shank. In the region of the intermediate portion 75, and upwardly therefrom, the passageway is uniformly of slightly larger diameter than the uniform diameter of the passageway 80 therebelow. A plurality of radially spaced inwardly and downwardly converging air passageways 81 lead from the shoulder 74 to the yarn passageway 80, the junctions of the passageways 81 with the passageway 80 being in a plane with or adjacent shoulder 72. It is therefore seen that the axes of the air passageways 81 form acute angles, respectively, with the axis of the yarn passageway 80. The outer portion of each air passageway 81 is of enlarged diameter, as at numeral 82, so as to permit the ready passage of air to passageways 81.

The opposite ends of the yarn passageway are counterbored to receive the tubular needle element 83 and the tubular throat member 84. The needle element 83 and throat member 84 are each hollow cylindrical elements having right cylindrical inner ends and inside diameters corresponding to the diameter of passageway Si), the throat member 84 being press tted by one end portion into the cap 76 so as to protrude an appreciable distance above the cap 76, and the tip 83 being press iitted by one end into the base portion 71 of the shank to protrude downwardly therefrom.

The upper or entrance end of the throat member 84 is belled out to provide a frusto-conical downwardly tapered lip 85 which merges with the cylindrical portion of the throat member 84. The lower or tip end of the needle element 83 is beveled to provide an elliptical rearwardly and downwardly opening discharge end 86 provided at its lowermost portion with a rounded point or tip 87 and at its uppermost portion or apogee with an arcuate yarn exit 88.

It is now seen that the passageways 89 and 89a, respectively, of the needle element 83 and the throat element 84, are axially aligned with yarn passageway 80 and with each other so as to provide an uninterrupted open yarn channel in the needle 5S from the lip 85 to the inclined opening at the discharge end 86 of the needle 55, the air introduced through the air passageways 81 urging the yarn 50 in the direction of tip 87.

For mounting the needles 55 on the needle carrier 54, the upper plate 57 is provided with a plurality of staggered holes, such as hole 90, arranged in two or more parallel rows along the length of the plate 57, the transverse spacing, i.e., the spacing lengthwise of the plate 57 and transversely of the feed of the backing material 30, being equal between adjacent holes in the rows. A set screw, such as set screw 79, is provided for each hole 90.

Vertically aligned, respectively, with each hole 90 is a second hole in the lower plate 58. Each second hole ini cludes a small diameter hole 91 bored from the lower plate portion of the plate 58 or as an initial hole and a larger diameter counterbore or hole 92 bored from the upper portion of the plate.

T he diameter of hole 90 corresponds to the diameter of cap 76, the diameter of hole 91 corresponds to the diameter of needle element 83 and the diameter of hole 92 corresponds to the diameter of base 71, the holes 90, 91 and 92 being slightly larger than the corresponding elements of the needle 5S.

A needle 55 is installed on the needle carrier 54 by being inserted into one group of vertically aligned holes 90, 91 and 92, whereby the needle element 83 projects through hole 91 and protrudes beneath the needle carrier 54. When needle 55 is properly positioned, as illustrated in FIG. 4, the lower portion of base 71 is received in hole 92 and the cap 76 is received in hole 90.

An air seal grommet or gasket 93, below the base 71 and surrounding the upper portion of needle element 83, is received in the lower portion of hole 92 and limits the downward movement of the needle 55. The set screw 79 which protrudes into the recess 78 prevents upward movement of needle 55 and positions the needle 54 with the discharge end 86 facing rearwardly. The set screw 79 also prevents inadvertant rotation of the needle 55.

It is now seen that any one of the needles 55 may be readily and easily replaced by simply loosening its set screw 79 and lifting the needle 55 out of carrier 54. From time to time the replacement of needles 55 may be necessary because the tip 87 has become worn; however, breakage of needles is practically non-existent, and the needle 55 being cooled by air emergiing from the needle 55 does not overheat readily. Since the needles 55 remain stationary, there is little likelihood of a needle 55 becoming misaligned due to vibration. Furthermore, the likelihood of the yarn 50 becoming jammed in the needle 55 is reduced to a minimum because the air urges the yarn 50 out of the discharge end 86 during each cycle. Also, the glue joints in yarn 50 are not subjected to great stress in passing through the needle 55.

It will be understood that the needles 55 are respectively vertically aligned with the recesses 32, as seen in FIG. 6, there being a rib 33 in a vertical plane between` each pair of needles 55. The tips 87 of all needles 55 are preferably disposed in the same horizontal plane, i.e., in a plane parallel to the plane of th upper surface of the deflector block 29. The tips 87 should also be disposed as close to the plane of the upper surface of deflector block 29 (at dead center) as is practical, to leave only sufficient space therebetween for the passage of backing material 30. Therefore, the movement of the portion of backing material 30 by the detlector block 29 need be only slightly greater than the vertical distance from tip 87 to edge 88, i.e., suicient for the discharge end 86 of the needles 55 to penetrate the backing material 30 asblock 29 moves from bottom dead center to top dead center. Therefore, only a small amplitude of reciprocation is necessary for deflector block 29. This and other factors permit the machine, if operating properly, to be operated at very high speed. Indeed, it is believed that a machine of the type here disclosed could be operated at approximately 3,000 r.p.m. for extended periods of time without shut down.

Stripper mechanism While the machine may be found to operate properly without any mechanism for positively removing the backing material 30 from the needles 55 during the travel of the retraction of the deilector block 29, it is believed preferable to provide a stripper mechanism which assures the removal of the backing material 30 from the tip portions of needles 55. This Astripper mechanism includes a stripper plate 100 which is of the same general configuration as a throat plate of a conventional tufting machine. The stripper plate 100 is a flat rectangular polished metal bar having a smooth flat lower surface. The rear edge of the stripper plate 100 is provided with a plurality of rearwardly opening apertures or open ended U-shaped slots 101 corresponding in number and position with the needles 55. The stripper plate 100 lies flat over the upper surface of the backing material, immediately above the upper surface of the deflector plate 29. In such a position, the slots 101 are respectively aligned with the needles 55, the slots 101` for the needles 55 in the front row of needles bein-g longer than the slots for the needles 54 in the back row of needles 55, and all lslots being suiliciently long that the inner ends of the slots terminate forwardly of their respective needles 55.

The function of the stripper plate 100 is to ride adjacent the upper surface of the 'backing material 30 so as to remove the same from needles 55 during the retraction of the deflector block 29. To accomplish this purpose, the stripper plate 100 may simply be spring bia-sed downwardly. It is preferred, however, that a means be provided for reciprocating the stripper plate 100 in synchronization with the reciprocation of the deflector block 29. To provide such a means, the stripper plate 100 is carried by a reciprocator block 102, the block 102, in turn, being carried by the lower ends of a plurality of vertically disposed, transversely spaced, reciprocator rods 103, seen in FIGS. 1 and 3.

The rods 103 pass upwardly through the bottom of a control bar housing 104 and thence through a transverse control bar 105, being secured to the bar 105 for movement therewith, the upper end portions` of the rods 103 passing through the top of the housing ]l04 and terminating outwardly thereof. The housing 104 is carried in a stationary position between the end members 11, forwardly of the needle carrier 54. The housing 104 journals the rods 1,03 for vertical sliding movement, as dictated by the control bar 105.

At the back of housing 104 are one of a plurality of slide blocks, such as slide block 106, secured in place by bolts 107. The control bar 105 is dovetailed in the slide block 106 so that it may move vertically with respect thereto.

The end portions of the control bar 105 extend Within the end members 11 and are provided with vertically disposed racks, such as rack 108. The racks, lsuch as rack 108i, mesh with segmented pinions, such as pinion 109, each pinion being pivotally carried by a pivot pin, such as pivot pin 110, and being rigidly connected to a forwardly extending lever, such as lever 111. The forward end of lever 111 is -pivotally connected to a rocker arm 112, the lower end of which extends generally downwardly within the end member 11 and is connected at its lower end to a bearing `sleeve 113 carried by an eccentrically mounted circular cam 114 on the main drive shaft 17. It will be understood that the other lever, such as lever 111, is provided with a similar mechanism for reciprocating it from shaft 17 so as to balance and synchronize the movement of the racks, such as rack 108, on both ends of control bar 105.

' The elements above described for reciprocating stripper plate 100 are so dimensioned that a reciprocatory motion of approximately the same amplitude is imparted to stripper plate 100 so as to maintain the gap between deflector -bar 29 and stripper plate 100 constant, throughout the cycle of reciprocation of stripper plate 100 and deilector bar 29.

Yarn control mechanism;

While there are generally two types of yarn control mechanisms which can be used for controlling the feed of yarn to the needles 55, one being a type which restrains the 4feed of yarn to the needles according to a prescribed pattern and the other being a type which positively delivers varying amounts of yarn to the needles according to a prescribed pattern, it is preferable to employ a yarn control mechanism which positively delivers the yarn since less air f-or urging the yarn 50 out of the needles 55 is required where positive delivery is employed.

According to the present invention, a suitable yarn control mechanism, denoted generally by numeral 120, is mounted on the fr-ame of the machine immediately above the throats of entrance end, i.e., lips 85 of needles 55.

The yarn control mechanism selected for purpose of illustration is known in the trade as a slat attachment or notch bar attachment and is exemplified in U.S. Patent No. 3,089,442.

In more detail, the yarn control mechanism 130 includes a pair of opposed end frames 121 mounted on the tops of the end members for rotation a pair of opposed upper sprocket shafts 122 and a pair of opposed lower sprocket shafts 123, the sprocket shafts 122 being vertically above the sprocket shafts 123. As seen in FIG. 2, the sprocket shafts 123 are respectively provided with sprockets 124, outwardly of one of the end frames 121. An endless chain passing around an idler sprocket 126 and thence below one of the sprockets 124 and above the other of sprockets 124 provides a drive means for rotating the shafts in opposite directions, the right shaft 12.3 in FIG. 2 being rotated counterclockwise and the left shaft 123 in FIG. 2 being rotated in an opposite or clockwise direction in timed relationship to each other. Power for chain 125 is 11. The end frames 121 support 1 1 supplied from the main drive shaft 17. Thus the rotation of shafts 123 is :synchronized with the rotation of shaft 17 Inwardly of end frames 121, the shafts 122 are provided with sprockets 127 while the shafts 123 are provided with sprockets 128, there being two sprockets 127 or 128 for each shaft 122 or 123. Continuous pairs of chains 129, leading from opposite directions, pass respectively over the sprockets 127 and 128 to provide pairs of spaced, opposed, parallel, vertically disposed flights of chains moving downwardly between the frames 121. The chains 129 are appropriately supported 'by idler sprockets (not shown) outwardly of the sprockets 127 and 128.

Carried by each pair of chains 129 are a plurality of spaced parallel slots or notch bars 130, the notch bars 130 on one pair of chains 129 intermeshing with the notch bars 130 of the other pair of chains 129 as they are carried along their vertical flights in a downward direction.

It will be understood that the bars in one or both groups of notch bars 130 are provided with a plurality of outwardly opening notches (not shown) of varying depth so that the yarns 50, which pass between the intermeshing bars 130 and are received in the notches, are deviated from their parallel paths toward the needles 55 by varying amounts. As is well known, the notches (not shown) in the notch bars 130 create a prescribed or predetermined pattern based upon the amounts of yarns 50 which are delivered to the needles 55. In other words, if a particular yarn 50 is deviated by the intermeshing notch bars 130 to a great extent, a greater amount of the yarn 50 is delivered from the discharge end 131 of the yarn control mechanism 120; and if the yarn 50 is delivered to the discharge end 131 with a lesser amount of deviation, a lesser amount of said yarn 50 is delivered to the discharge end 131.

It is important for best results, though not indispensible, that the discharge end 131 of the yarn control mechanism,120` discharge downwardly, as close as possible to the throat or lips 85 and that the discharge end 131 be vertically above, aligned along the line of travel of yarns 50 with the needles 55. Thus, yarns 50 fed from discharge end 131 travel in a short, essentially straight path into needle 55, whereby the yarns 50 are subjected to no undue abrasion or stretching and do not readily break. Since the needles 55 are stationary, there is a constant or fixed distance between the discharge end 131 and needles 5S, regardless of the phase of cycling of the machine.

At this point it should be mentioned that, while a yarn control mechanism for delivering varying amounts of yarns 50 to the needles 55 has been disclosed, conventional yarn feed rollers for delivering uniform amounts of yarn as well as other feed mechanisms for delivery of uniform amounts of yarns 50 to the needles 55 could be employed without departing from the scope of this invention. Of course, when such yarn control mechanisms for delivery of uniform amounts of yarn are employed, tufted fabric having uniform pile loops would result.

Below the yarn control mechanism 120, at the upper ends of end members 11, is a shield plate 140 which extends across the machine from one end member 11 to the other. The shield plate 140 is supported by a plurality of 'transverse angle irons 141 which extend between the end members 11. A plurality of holes or apertures 142 are provided in the shield plate 140 through which the throat members 84 of the needles 55 project. The purpose of the shield plate is to prevent oil or other lubricant from dripping from the yarn control mechanisms 120 onto the backing material. The shield plate 140 also prevents lint created by the tufting operation from being received in the needles 55. j

Referring now to FIGS. 7 and 8, it will be seen that, if desired, a vacuum system may be employed for imparting a uid differential pressure to the needles 55, i.e., the yarns 50 within the needles 55. This vacuum system may entirely replace the compressed air system of the previous embodiment or it may be utilized in conjunction with, and as an adjunct to, the compressed air system. In FIG. 7, since the vacuum system, as illustrated, has been simply added to the machine disclosed hereinabove, only that portion of the machine of FIGS. 1 through 6 which is directly involved has been illustrated, retaining the original numbers thereof.

In the present modified form, as illustrated in FIGS. 7 and 8, a U-shaped pan, denoted generally by numeral 200, is -supported on top of housing 13, the pan 200 being provided with a flat base 201 secured against the upper surface of housing 13 and having appropriate holes therein through which the bushings 27 extend. The U- shaped pan 200 also includes a front plate 202 projecting upwardly and forwardly from the front edge of base 201 and a rear plate 203 projecting upwardly and rearwardly from the rear edge of base 201.

The upper edge of front plate 202 is turned outwardly to provide a horizontally disposed front slide plate 204 immediately below and parallel to the path of travel of the backing material 30. The front slide plate 204 protrudes an appreciable distance toward the front rollers 34 and is turned downwardly for providing a downwardly and forwardly extending guide flange 205 for guiding the backing material 30 onto the slide plate 204. Flanges, such as flange 198, through which bolts, such as bolt 199, pass, secure the front slide plate 202 to the inner surfaces of end members 11.

The rear plate 203 terminates appreciably below the plane of backing material 30 and is provided with an adjustable extension, denoted generally by numeral 206. Extension 206 includes, at flat baffle 207 aligned with plate 203 and having a lower offset flange 208. Flange 208 overlaps the upper edge portion of plate 203 and is provided with a plurality of vertically disposed slots, such as slot 209, these slots being aligned with holes in the upper edge portion of plate 203 for receiving therethrough bolts, such as bolt 210. Bolt 210 has a head on the inner side of plate 203 which seals the hole through which it projects and threadedly receives a nut 211 outwardly of the ange 20S. It is therefore seen that the position of bafe 207 may be altered so as to extend or retract bale 207 and that when nuts, such as nut 211, are tightened, air will not readily pass between the plate 204 and baie 207.

The upper end of bale 207 is provided with a rearwardly extending slide plate 212 which has at its rearmost edge a downwardly turned lip or guide flange 213. Downwardly turned side flanges, such as flange 214, on the opposite sides of slide plate 212 abut the end member 11 yand are each provided with an inclined slot 215 through which a bolt 216 projects for threadedly engaging the end member 11. Slots, such as slot 215, are parallel to battle 207 so as to permit adjustment of the bale 207 along its plane.

Normally, the slide plate 212 is `disposed below the plane of slide plate 204 and is in spaced relationshipto backing material 30 passing thereover. Thus, sufficient space is provided between the backing material 30 and the plate 212 to accommodate the tufts or loops 51.

It will be understood that the U-shaped pan 200 extends from one end member 11 to the other and is welded or otherwise sealed thereto, except for the adjustable extension 206. The purpose of making the extension adjustable is to permit the space between the backing material 30 and the slide plate 212 to provide `for a variation in pile height of loops 51.

A suitable vacuum pump (not shown) is connected to pipe 217 which in turn is carried by front plate 202 and communicates with the interior of pan 200 for drawing a vacuum in the `vacuum chamber defined by pan 200 and the backing material 30 passing thereover. The opposite ends of the vacuum chamber, thus produced, are closed by adjustable, complementary end plates, such as end 13 plate 220, which ride within the pan 200 and are adjusted to abut the selvages of the backing material 20.

In more detail, each end plate 220 is a flat trapezoidal member having inwardly turned flanges 221, 222 and 223 along Vits bottom and side edges, the flange 221 riding on the inner surface of base 201 and the flanges 222 and 223, respectively, riding along the inner surfaces of plates 202 and 203. Horizontally disposed slots, such as slot 224, are provided in the flanges 222 and 223, and these slots receive bolts, such as bolt 225, which project outwardly through the `liront and rear plates 202 and 203, respectively. The bolts, such as ybolt 225, are provided, outwardly of plates 202 and 203 with nuts, such as nut 226. By loosening the nuts, such as nut 226, the end plate 220 may be adjusted transversely of the machine so as to accommodate different width. backing -material 30.

Since the deflect-or bar 29 and the mounting block 28 protrude outwardly of the end Iplates, Such as plate 220, an upwardly open slot 227 is provided in the central portion of the end plate 220 to permit free reciprocation of the deiiector -bar 29 and mounting block 28. For sealing this slot 227, Abelow the deflector bar 29, the deflector bar 29 and mounting block 28 carry a flat shield 228 which is sufficiently larger than the slot 227 to close the same, regardless of the position of the deflector bar 29 along its path of reciprocation. Preferably, shield 228 is a fiat, rectangular member having rounded upper corners and an upper edge which terminates in the plane of the upper surface of deflector bar 29. The central portion of the shield 228 is cut out to provide an upwardly opening aperture conforming to the configuration of the sides `and bottom portions of the deiiector bar 29 and the mounting block 28.

Connected to the inner surface of shield 228 and also conforming to the shape of the sides and bottom portions of the deflector bar 29 and mounting block 28 is a U-shaped sleeve 230, the outer end 'of which is secured to the shield 228 for carrying the same. The sleeve 230 has horizontally disposed slots, such as slot 231, through which bolts 232, respectively, project and are threadedly received in either the deflector bar 29 or the mounting block 28, as the case may be. It is therefore seen that the position of the shield 228 may lbe varied along the length of the deflector bar 29 so as to ride against the surface of end plate 220, regardless of its position. v

Above the backing material 30,the end plate 220 is provided with a pair of inwardly turned flanges 23S and 236 which are inclined inwardly, i.e., toward needles 55 and upwardly, the ilanges 235 and 236 terminating at the upper end of slot 227. These flanges 235 and 236 prevent the selvage of backing material 30 from jumping outwardly of the end plate 220 when the central portion of backing material 30 is reciprocated.

For holding the backing material 30 against the slide plate 204, a hold down roller 240 is provided over the slide plate 204, the roller being carried for rotation by the end .members 11. A similar hold down roller 241 is provided over slide plate 212, Ibut is spaced from the slide plate 212 suiiicie'ntly for the backing material 30 and the tufts therein to pass therebetween.

It will be understood that upon reciprocation of the central transverse portion of backing material 30 by the deflector bar 29, loops 51 will be created in backing mate# rial 30. Since a vacuum is created below the backing material 30 -by the vacuum system previously described, the loops, after penetration of needles 55, will be sucked downwardly due to air rushing through the needles 55 to fill the vacuum, i.e., due to the fluid differential pressure.

Operation From the foregoingdescription, the operation of the device should be apparent. First, the .backing material 30 is fed tothe ,machine `from a roll of backing material (not shown), the backing material 30 passing around the infeed rollers 34, as indicated in FIG. 3, and thence across the 14 machine. The backing material 30 is then fed between the stripper plate and the ydefiector bar 29, and thereafter is fed to the outfeed rollers 35.

Yarns 50 from the creel (not shown) are fed through appropriate guides (not shown) and project downwardly over the entrance of yarn control mechanism in transversely parallel paths. Thence yarns 50 are passed through the yarn control mechanism 120, as indicated in FIG. 3, one yarn 50 being fed downwardly from the exit or discharge end 131 of the yarn control mechanism 120 to the throat of each of the needles 55 disposed therebelow. Each yarn 50 is fed through the passageway S0 of the needle and is discharged out of the discharge end 86, the ends of the yarns 50 being led rearwardly of the machine. Next, compressed air or other fluid under pressure is introduced to the pipe or pipes 62 so as to be capable of supplying this compressed air to the needles 55 in accordance with the dictates of the valve 63. The machine is now ready for operation. At this time, in the cycle of the machine, the solenoid 64 will be energized because the conimutator 66 has made a. circuit thereto. Thus the valve 63 is opened and air is introduced via the chamber of the needle carrier 54 and the air passageways 81 of each needle 55 into the passageways 80 and 89 of the needles 55. The air urges the yarns 50 downwardly so as to create loops, corresponding to the amounts of yarn fed by the yarn feed mechanism 120 to the respective needles 55.

It is significant to note that the tension on the yarns 50 from the time that the yarns 50 are discharged from the yarn control mechanism 120 is only approximately 30 grams and never exceeds 50 grams since, at all times, the only force exerted on yarns 50, in urging the yarn from the needles 55, is the liuid differential pressure applied by the air traveling in the yarn p-assageways 80 and 89.

As the backing material 30 is inserted onto the tips 87 of the needles 55, the needle element 83 progressively urges the warp and filling yarns (not shown) of the backing material apart to form an opening for receiving the yarn 50. The opening thus formed is aligned with the yarn 50 in the passageway 89, and after the opening has been created of a size corresponding to the needle element, an increment of yarn 50 is readily discharged through the opening by the fluid differential pressure on the increment of yarn. Of course, the size: of the opening appreciably exceeds the size (diameter) of the yarn 50, and the needle element 83 acts as a guide to hold open the hole; therefore, the yarn 50 is freely discharged through the opening to form a loop, such as loop 51. As the backing material 30 is withdrawn from the needle element 83, the yarn 50 for creating the loop remains in place and upon the creation of a subsequent hole for the yarn 50 in a subsequent cycle of the machine, the needle element 83 tends to cam the filling of backing material 30 toward a position for closing the first hole around the legs of the loop.

4Upon the downstroke of the detiector bar 29, the stripper plate 100 urges the backing material 30 ofrr of all needles 55 and the cycle is then repeated. Since the rollers 34 and 35 move the backing material 30 in the direction of arrow 38, the deflector bar 29 presents a new transverse portion of the backing material 30 to the needles 55 upon each new cycle of the machine. Thus the tufting operation continues with each new cycle.

It is to be understood that lthe length of a specific loop,

such as loops 51 and 52, is determined by the amount of yarn 50 fed to a needle 55 for creating that loop. Thus a specic loop may be any length desired. Since all yarn delivered to the needles 55 during a particular cycle will be utilized in creating a transverse row or rows of loops, such as loops 51 and 52 and their respective backstitches 53, a prescribed pattern may be created.4 Furthermore, there is no need for back drawing of the yarns 50 as would be required by conventional equipment. Contrary to the loops which are formed using conventional equipl ment, having loopers, the legs 160 of each loop 51 or 52 are aligned longitudinally with each other along the line of travel of the base fabric 30 and are also aligned with the back stitch 53.

The air emanating through the hollow needle 55 tends to uff out the loops 51 and 52, as these loops are being formed; and, therefore, a superior type of tufted fabric is produced. Indeed, since the taper of the discharge opening 86 is usually greater in vertical height than the thickness of the backing material 30, at one stage in each cycle, portions of this opening 86 are both above and below the backing material 30, thereby providing a relatively free path for any taken up of the back stitch 53; and since the air is directed downwardly against the loop at this time, the back stitch 53 will be drawn tightly against the backing material 30,' the needle 55 holding the weave of the backing material 30 open.

Since there are no loopers and no finite adjustment necessary in the present machine, the mechanism of the present machine will operate continuously for extended periods of time without shut down, except as may be necessary due to the breaking of the yarn (which is at a minimum). Indeed, the machine will operate for a considerably greater percentage of the time than prior art conventional machines.

The vibrations of the machine are markedly less than vibrations of a conventional tufting machine since the major reciprocating portions of the machine are located in the vicinity o-f the main drive shaft 17 and are, therefore, in close proximity t`o the feet 12 of the machine. Thus, no undue wear and noise due to reciprocation of the various parts should be expected. Furthermore, there is little danger of oil leaking onto the lbacking material 30 as it is being tufted. The air passing through the needles 55 also tends to keep the area clear of lint and permits the tufting operation to be observed by the operator.

It will be obvious to those skilled in the art that many variations may be made in the embodiment chosen for purpose. of illustrating the invention without departing from the scope of this invention as defined by the appended claims.

What is claimed as invention is:

1. In a machine for producing pile fabric of the type having a frame and means for feeding a backing material along a path of travel adjacent the frame, the cornbination therewith of a substantially stationary needle on said frame for holding adjacent its tip yarn to be received through said backing material, said needle being disposed at a suicient angle to the path of travel of said backing material that it may penetrate said backing material, the tip of said needle terminating adjacent the path of travel of said backing material, and means for reciprocating successive portions lof said backing material in a path onto and away from the tip of said needle as said successive portions of said backing material are positioned in the vicinity of said tip of said needle, the amplitude of reciprocation of said reciprocating means being sufficient for the tip of said needle during a portion of the cycle of reciprocation of each successive portion of said backing material to be on one side of the path of travel of said backing material and during another portion of said cycle to be on the other side of the path of travel of said backing material w-it-h said needle projecting through said backing material.

2. In a machine for producing pile fabric of the type having a frame and means for feeding a backing material along a predetermined path of travel in the frame of said machine, the combination therewith of a substantially stationary needle on said frame for holding adjacent its tip yarn to be received through said backing material, said stationary needle being disposed transverse to the path of travel of said backing material, the tip of said needle terminating adjacent the path of travel of said backing material, means for reciprocating successive portions of said backing material in a path onto and away from the tip of said needle as said successive portions of `said b-acking material are positioned in the vicinity of said tip of said needle, the amplitude of reciprocation of lsaid reciprocating means being sufficient for the tip of said needle during a portion of the cycle of reciprocation of each successive portion of said backing material to be on one side of the path of travel of said backing material wit-h the needle out of said backing material and during another portion of said cycle 4to be on the other .sde of the path `of travel of said backing -rnaterial with sai-d needle projecting through said backing material, an-d means operatively associated with said needle for supplying prescribed amounts of yarn to said needle.

3. In a tufting machine of the type having a frame, means to feed a backing material through said frame along a prescribed path of travel, a plurality of hollow needles disposed on one -side of the path of travel of the backing material for holding yarns to be sewn into the backing material, a yarn control mechanism for feeding prescribed amounts of yarns to said needles and means for expelling the yarns from said needles in amounts prescribed by said yarn control mechanism, the combination therewith of means for holding said hollow needles in a substantially stationary position, and means for reciprocating successive portions of said backing material toward and onto said tip portions of said needles and away from and off of said tip portions of said needles in timed relationship with said means for feeding the backing material through said tufting machine.

4. In a tufting machine of the type having a frame, means for feeding a backing material through said frame along a prescribed path, said feeding means including feed elements disposed on opposite sides of a tufting zone, a plurality of needles ldisposed in the tufting zone on one side of the path of travel of said backing material for holding yarns to be sewn into the backing matetrial, yarn control mechanism for lfeeding prescribed amounts of yarns to said needles, means on the other side of said path of travel of said backing material for reciprocating successive transverse portions of said backing material toward and onto said needles and away from and off of said needles in timed relationship with said means for feeding the backing material through said tufting machine.

5. In a machine for producing pile fabric the combination comprising a frame, means f-or feeding a backing material along la predetermined path of travel in the frame, a substantially stationary needle on said frame for lholding adjacent its tip yarn to be received through said backing material, said needle being disposed transverse to the path of travel of said backing material, the tip of said needle terminating adjacent the path of travel of said backing material, means for reciprocating successive portions of said backing material in a path onto and away from the tip of said needle as said succes-sive portions of said backing material are positioned in the vicinity of said tip of said needle, means operatively vassociated with said needle for supplying prescribed amounts of yarn to said needle, and means operatively associated with said needle for assuring that as the successive portions of said backing material are withdrawn from the needle a portion of the yarn carried by said needle remains with said backing material.

6. In a tufting machine of the type having a frame, means including feed rollers disposed on opposite sides of a tufting zone for feeding a backing material along a prescribed path of travel through said tufting zone, the feed rollers holding the backing material taut as the backing material is fed along its path of travel, a plurality of hollow needles disposed in the tufting zone on one side of the path of travel of the backing material and transversely of the path of travel of the backing material for holding yarns to be tufted into the backing material,

yarn control mechanism for feeding prescribed amounts of yarns to said needles, and means for supplying fluid differential pressure to said yarns for urging the yarns from said needles in amounts prescribed by said yarn control mechanism, the combination therewith of means for holding said hollow needles in a substantially stationary position, and means for reciprocating successive transverse portions of said backing material toward and onto the tip portions of said needles and away from and E of said tip portions of said needles in timed relationship with said means for feeding the backing material through said tufting machine.

7. A tufting machine comprising a `frame, a yarn control mechanism adjacent said frame, a needle carrier mounted in a stationary position on said frame adjacent said yarn control mechanism, said yarn control mechanism having a discharge end disposed adjacent said needle carrier, a plurality of hollow needles carried by said needle carrier, each of said hollow needles being provided with a throat at one end and a tip at its other end, each of said hollow needles having a yarn passageway from said throat to said tip, the throats of said needles being disposed immediately adjacent the discharge end of said yarn control mechanism for receiving in direct paths from said yarn control mechanism yarns discharged from said yarn control mechanism, means for feeding a backing material along a predetermined path adjacent the tips of said needles, a deflector bar disposed adjacent the predetermined path of said Abacking material, a stripper plate adjacent the tips of said needles, means for reciprocating said deector bar and said stripper plate in timed relationship at an amplitude suicient that said deflector bar and said stripper plate urge successive transverse portions of said backing material onto the tips of said needles and olf of the tips of said needles.

8. In a machine for producing pile fabric of the type having a frame and means for feeding a backing material along a predetermined path of travel in the frame, the combination therewith of a substantially stationary needle on said frame for holding adjacent its tip, yarn to be inserted through said backing material, said stationary needle being disposed transverse to the path of travel of said backing material, the tip of said needle terminating adjacent the path of travel of said backing material, means A for reciprocating successive portions of said backing material in a path onto and away from the tip of said needle as said feeding means moves said successive portions of said backing material past said tip of said needle, the arnplitude of reciprocation of said reciprocating means being sulicient for the tip of said needle during a portion of the cycle of reciprocation of each successive portion of Said backing material to be on one side of the path of travel of saidbacking material with the needle out of said backing material and during another portion of said cycle to be on the other side of the path of travel of said backing material with said needle projecting through said backing material, means operatively associated with said needle for supplying prescribed amounts of yarn to said needle, and means operatively associated with said needle for assuring that as the successive portions of said backing material are withdrawn from the needle a portion of the yarn carried by said needle remains with said backing material.

9. In a tufting machine of the type having a frame, means including feed rollers disposed on opposite sides of a tufting zone for feeding a backing material through said tufting zone, the feed rollers holding the backing material taut as the backing material is fed along its path of travel, a plurality of hollow needles disposed in the tufting zone on one side of the path of travel of the backing material and transversely of the path of travel of the backing material for holding yarns to be tufted into the backing material, a yarn control mechanism arranged for feeding prescribed amounts of yarns to said needles, and fluid supply means for supplying fluid through said hollow needles for expelling the yarns from saidncedles in amounts prescribed `by said yarn control mechanism, the combination therewith of means for holding said hollow needles in a substantially stationary position, and means for reciprocating successive transverse portions of said backing material toward and onto the tip portions of said needles and away from and off of said tip portions of said needles in timed relationship with said means for feeding the backing material through said tufting machine.

10. A tufting machine comprising a frame, a yarn control mechanism adjacent said frame and having a discharge end disposed in a downwardly discharging direction, a needle carrier mounted in a stationary position on said frame below said yarn control mechanism, a plurality of hollow needles carried by said needle carrier, each of said hollow needles being provided with a throat at its upper end and a tip at its lower end, each of said hollow needles having a yarn .passageway from said throat to said tip, the throats of said needles being disposed immediately below the discharge end of said yarn control mechanism for receiving in direct paths from said yarn control mechanism yarns discharged from said yarn control mechanism, means for feeding a backing material along a predetermined path beneath the tips of said needles, a deector bar disposed adjacent the predetermined path of said backing material, a stripper plate adjacent the tips of said needles, meansfor reciprocating said dellector bar and said stripper plate in timed relationship at an amplitude sulicient that said defiector bar and said stripper plate insert successive transverse portions of said backing material onto the tips of said needles and olf of the tips of said needles.

11. A tufting machine comprising a frame, a yarn control mechanism adjacent said frame and having a discharge end disposed in la downwardly discharging direction, a needle carrier mounted on said frame below said yarn control mechanism, a plurality of hollow needles projecting through said needle carrier, each of said hollow needles being provided with a throat at its upper end and a tip at its lower end, each of said hollow needles having a yarn passageway from said throat to said tip, the throats of said needles being disposed immediately below the discharge end of said yarn control mechanism for receiving in direct paths from said yarn control mechanism yarns discharged from said yarn control mechanism, means for feeding a backing material along a predetermined path beneath the tips of said needles, a deflector bar disposed adjacent the predetermined path of said backing material, means for imparting reciprocatory movement to said deilector bar in a direction toward and. away from said needles, a stripper plate adjacent the tips of said needles, means for reciprocating said stripper plate in timed relationship to the means for reciprocating said deilector bar, said deliector bar being provided with recesses vertically aligned with said needles and disposed longitudinally of the path of travel of said backing material, said deector bar and said stripper plate being so disposed with respect to said needles and both of said reciprocating means being reciprocated at an amplitude sufficient that said deilector bar and said stripper plate upon movement of said backing material along its path of travel urge successive transverse portions of said backing material onto the tips of said needles and olf of the tips of said needles, and means for urging said yarns outwardlyv from the tips of said needles.

12. A tufting machine comprising a frame, a needle carrier mounted in a stationary position on said frame, said needle carrier having a fluid chamber, conduit means communicating with said uid chamber for supplying uid under pressure to said chamber, a plurality of hollow needles projecting from said needle carrier, each of said hollow needles being provided with a throat at its upper end and a tip at its lower end, each of said hollow needles having a yarn passageway from said throat to said tip and a fluid passageway communicating: with said iluid chamber and said yarn passageway for supplying fluid from said fluid chamber to said yarn chamber, said iluid passageway being so disposed that uid from said uid chamber passing through said fluid passageway urges yarn in said yarn passageway toward the tip of its needle, means for feeding a backing material along a predetermined path beneath the tips of said needles, a main drive shaft below said needles in said frame, a dellector bar disposed adjacent and Ibelow the predetermined path of said backing material, means interconnected between said deflector bar and said main drive shaft for imparting reciprocatory movement to said deflector bar upon rotation of said main drive shaft, motor means for rotating said main drive shaft, a stripper plate adjacent the tips of said needles for urging said backing material away from said tips of said needles, said deflector bar being so disposed with respect to said needles and said deflector bar reciprocating means being reciprocated at an amplitude sufficient that upon movement of said backing material along its path of travel said deflector bar periodically urges successive transverse portions of said backing material `onto the tips of said needles, and iluid control means for controlling the iiow of said fluid whereby increments of yarns are discharged from said tips after each transverse portion of backing material has been inserted onto the tips of said needles.

13. A tufting machine comprising a frame, a yarn control mechanism adjacent said frame and having a discharge end disposed in a downwardly discharging direction, a needle carrier mounted in a stationary position on said frame below said yarn control mechanism, said needle carrier having a fluid chamber, conduit means communicating with said fluid chamber for supplying fluid under pressure to said chamber, a plurality of hollow needles projecting from said needle carrier, each of said hollow needles being provided with a throat at its upper end and a tip at its lower end, each of said hollow needles having a yarn passageway from said throat to said tip and a fluid passageway communicating with said fluid chamber and said yarn passageway for supplying fluid from said iiuid chamber to said yarn passageway, said iiuid passageway being so disposed that fluid from said fluid chamber passing through said Huid passageway urges yarn in said yarn passageway toward the tip of its needle, the throats of said needles being disposed immediately below the discharge end of said yarn control mechanism for receiving in direct paths from said yarn control mechanism yarns discharged from said yarn control mechanism, means for feeding a backing material along a predetermined path beneath the tips of said needles, a main drive shaft below said needles in said frame, a deflector bar disposed adjacent the predetermined path of said backing material, means interconnected between said detlector bar and said main drive shaft for imparting reciprocatory movement to said deflector bar upon rotation of said main drive shaft, motor means for rotating said main drive shaft, a stripper plate adjacent the tips of said needles, means for reciprocating said stripper plate in timed relationship to said means for reciprocating said deilector bar, said dei-lector bar being provided with recesses aligned with said needles and disposed longitudinally of the path of travel of said backing material, said deflector bar and said stripper plate being so disposed with respect to said needles and both of said reciprocating means being reciprocated at an amplitude suflicient that upon movement of said backing material along its path of travel successive transverse portions of said backing material are urged onto the tips of said needles and olf of the tips of said needles, and uid control means for controlling the flow of fluid into the yarn passageways of said needles so that increments of yarns the lengths of which are controlled by said yarn control mechanism are discharged from said tips after each transverse portion of backing material has been inserted onto the tips of said needles.

14. In a process of producing pile fabric, holding a needle the tip portion of which carries yarn in a prescribed stationary position, arranging a lirst portion of a backing material adjacent said tip portion of said needle, moving said first portion of said backing material toward and onto said tip portion of said needle, inserting a first increment of said yarn into said backing material and removing said backing material from said needle with said first increment of said yarn carried in said rst portion of said backing material, thereafter arranging a second portion of said backing material adjacent said tip portion of said needle, moving said second portion of said backing material toward and onto said tip portion of said needle, inserting a second increment of said yarn into said backing material and removing said backing material from said needle with said second increment of said yarn carried in said second portion of said backing material.

15. In a process of tufting, the steps of holding an increment of yarn in a prescribed position, passing a backing material along a prescribed path toward said increment of yarn, forming a hole aligned with said increment of yarn in said backing material as said backing material is moved toward said increment of yarn, and continuing the movement of said backing material in its direction of movement for a sufficient distance that the portion of backing material defining said hole is passed around said increment of yarn.

16. In a process of tufting, the steps of holding an increment of yarn in a prescribed position, passing a backing material along a prescribed path toward said increment of yarn, forming a hole aligned with said increment of yarn in said backing material as said backing material is moved toward said increment of yarn, and continuing the movement of said backing material in its direction of movement for a sucient distance that the portion of backing material defining said hole is passed around said increment of yarn, thereafter moving said increment of yarn in a direction opposite the direction of movement of said backing material.

17. In a process of tufting, the steps of holding an increment of yarn in a prescribed position, passing a backing material along a prescribed path toward said increment of yarn, forming a hole aligned with said increment of yarn in said backing material as said backing material is moved toward said increment of yarn, and continuing the movement of said backing material in its direction of movement for a sufficient distance that the portion of backing material dening said hole is passed around said increment of yarn, thereafter moving said increment of yarn in a direction opposite the direction of movement of said backing material, and then moving said backing material in said opposite direction.

18. In a process of tufting, the steps of positioning backing material in a prescribed position, positioning yarn in a prescribed position adjacent one side of the backing material, moving the backing material in the direction of the yarn as the yarn is maintained substantially stationary for inserting a portion of the yarn through the backing material, and applying a vacuum to the opposite side of the backing material for aiding the movement of the yarn through the backing material.

19. In a tufting machine, the combination comprising a plurality of needles having tips for penetrating a backing material to insert yarn into the backing material to form tufts therein, means mounting said needles in stationary positions, and means for moving a backing material onto and off of the tips of said stationary needles whereby tufts are formed in the backing material. e

20. A tufting machine as recited in claim 19 wherein said needles are hollow having yarn inlets and outlets and further comprising a yarn control mechanism having a discharge end immediately adjacent the inlets of said hollow needles for feeding controlled lengths of yarn to said needles.

21. In a tufting machine the combination comprising means to feed a backing material to be tufted through the machine along a prescribed path of travel, a hollow needle disposed on one side of said path of travel for carrying yarn through the hollow portion of the needle, an end portion of said needle projecting toward said path of travel, means for moving successive portions of the backing material laterally toward and away from said hollow needle to Ialternately impale said backing material on and remove it from said end portion of said hollow needle, and vacuum means for applying a vacuum to the backing material from the other side of said path of travel to urge the yarn carried by said needle out of said end portion of said needle.

22. In a tufting machine the combination comprising means for feeding a backing material through the machine along a prescribed path of travel, a plurality of needles for holding yarns to be inserted through the backing material, said needles having tips disposed adjacent said path of travel on one side thereof, means for reciproeating successive portions of said backing material alternately into and out of an impaled relationship relative to said needles for receiving said yarns as tufts in said backing material when thus impaled, and vacuum creating means disposed on the other side of said path of travel and operatively associated with said reciprocating means for elongating the tufts as the tufts are produced.

References Cited UNITED STATES PATENTS 1,863,049 6/1932 Hermann 112-79 2,842,079 7/ 1958 Rice 112-79 2,866,424 12/1958 Masland 112-79 3,039,170 6/1962 Marshall 112-79 3,089,442 5/ 1963 Short 112-79 3,225,723 12/1965 Wilkes 112-80 JORDAN FRANKLIN, Primary Examiner.

20 J. R. BOLER, Assistant Examiner. 

15. IN A PROCESS OF TUFTING, THE STEPS OF HOLDING AN INCREMENT OF YARN IN A PRESCRIBED POSITION, PASSING A BACKING MATERIAL ALONG A PRESCRIBED PATH TOWARD SAID INCREMENT OF YARN, FORMING A HOLE ALIGNED WITH SAID INCREMENT OF YARN IN SAID BACKING MATERIAL AS SAID BACKING MATERIAL IS MOVED TOWARD SAID INCREMENT OF YARN, AND CONTINUING THE MOVEMENT OF SAID BACKING MATERIAL IN ITS DIRECTION OF MOVEMENT FOR A SUFFICIENT DISTANCE THAT THE PORTION OF BACKING MATERIAL DEFINING SAID HOLE IS PASSED AROUND SAID INCREMENT OF YARN.
 19. IN A TUFTING MACHINE, THE COMBINATION COMPRISING A PLURALITY OF NEEDLES HAVING TIPS FOR PENETRATING A BACKING MATERIAL TO INSERT YARN INTO THE BACKING MATERIAL TO FORM TUFTS THEREIN, MEANS MOUNTING SAID NEEDLES IN STATIONARY POSITIONS, AND MEANS FOR MOVING A BACKING MATERIAL ONTO AND OFF OF THE TIPS OF SAID STATIONARY NEEDLES WHEREBY TUFTS ARE FORMED IN THE BACKING MATERIAL. 